UVLED Apparatus for Curing Glass-Fiber Coatings

ABSTRACT

A UVLED apparatus and method provide efficient curing of an optical-fiber coating onto a drawn glass fiber. The apparatus and method employ one or more UVLEDs that emit electromagnetic radiation into a curing space. An incompletely cured optical-fiber coating, which is formed upon a glass fiber, absorbs emitted and reflected electromagnetic radiation to effect improved curing.

CROSS-REFERENCE TO PRIORITY APPLICATION

This application hereby claims the benefit of U.S. Patent ApplicationNo. 61/141,698 for a UVLED Apparatus for Curing Glass-Fiber Coatings(filed Dec. 31, 2008), which is hereby incorporated by reference in itsentirety.

FIELD OF THE INVENTION

The present invention embraces an apparatus and a method for curingcoatings on drawn glass fibers.

BACKGROUND

Glass fibers are typically protected from external forces with one ormore coating layers. Typically, two or more layers of coatings areapplied during the optical-fiber drawing process (i.e., whereby a glassfiber is drawn from an optical preform in a drawing tower). A softerinner coating layer typically helps to protect the glass fiber frommicrobending. A harder outer coating layer typically is used to provideadditional protection and to facilitate handling of the glass fiber. Thecoating layers may be cured, for example, using heat or ultraviolet (UV)light.

UV curing requires that the coated glass fiber be exposed to highintensity UV radiation. Curing time can be reduced by exposing thecoating to higher intensity UV radiation. Reducing curing time isparticularly desirable to permit an increase in fiber drawing linespeeds and thus optical-fiber production rates.

Mercury lamps (e.g., high pressure mercury lamps or mercury xenon lamps)are commonly used to generate the UV radiation needed for UV curing. Onedownside of using mercury lamps is that mercury lamps require asignificant amount of power to generate sufficiently intense UVradiation. For example, UV lamps used to cure a single coated fiber(i.e., one polymeric coating) may require a collective power consumptionof 50 kilowatts.

Another shortcoming of mercury lamps is that much of the energy used forpowering mercury lamps is emitted not as UV radiation, but rather asheat. Accordingly, mercury lamps must be cooled (e.g., using a heatexchanger) to prevent overheating. In addition, the undesirable heatgenerated by the mercury lamps may slow the rate at which the opticalfiber coatings cure.

Furthermore, mercury lamps generate a wide spectrum of electromagneticradiation, such as having wavelengths of less than 200 nanometers andgreater than 700 nanometers (i.e., infrared light). Typically, UVradiation having wavelengths of between about 300 nanometers and 400nanometers is useful for curing UV coatings. Thus, much of theelectromagnetic radiation generated by mercury bulbs is wasted (e.g., 90percent or more). Additionally, glass fibers possess an exemplarydiameter of about 125 microns, which, of course, is much smaller thanthe mercury bulbs. Consequently, most of the UV radiation emitted by themercury lamps does not reach the glass fiber's uncured coating (i.e.,the energy is wasted).

It may thus be advantageous to employ UVLEDs, an alternative toconventional mercury lamps, to cure glass-fiber coatings. UVLEDstypically require significantly less energy and correspondingly generatemuch less heat energy than conventional UV lamps.

For example, U.S. Pat. No. 7,022,382 (Khudyakov et al.), which is herebyincorporated by reference in its entirety, discloses the use of UVlasers (e.g., continuous or pulsed lasers) for curing optical fibercoatings.

U.S. Patent Application Publication No. 2003/0026919 (Kojima et al.),which is hereby incorporated by reference in its entirety, discloses theuse of ultraviolet light emitting diodes (UVLEDs) for curing opticalfiber coatings. The disclosed optical fiber resin coating apparatusincludes a mold assembly in which a UV curable resin is coated onto anoptical fiber. Also at the mold assembly, the coated optical fiber isexposed to UV radiation from a number of UVLEDs to cure the UV coating.A control circuit may be used to control the UV radiation output fromthe UVLED array. For example, the control circuit may reduce the currentto one or more UVLEDs to reduce the intensity of emitted UV radiation.The control circuit may also be used to vary the intensity of the UVradiation as the optical fiber progresses through the mold assembly.

Even so, UVLEDs, though more efficient than mercury lamps, still waste asignificant amount of energy in curing glass-fiber coatings. Inparticular, much of the emitted UV radiation is not used to cure theglass-fiber coatings.

Therefore, a need exists for a UVLED apparatus that, as compared with aconventional mercury-lamp device, not only consumes less power andgenerates less unwanted heat, but also is capable of curing glass-fibercoatings with improved curing efficiency.

SUMMARY

Accordingly, the invention embraces a UVLED apparatus and associatedmethod for curing in situ optical-fiber coating. The apparatus andmethod employ one or more UVLEDs that emit electromagnetic radiationinto a curing space. An incompletely cured, coated glass fiber passesthrough the curing space, thereby absorbing electromagnetic radiation toeffect curing of the optical-fiber coating.

An exemplary UVLED apparatus includes one or more UVLED-mirror pairs.Each UVLED-mirror pair includes one or more UVLEDs capable of emittingelectromagnetic radiation and one or more mirrors (or other reflectivesurfaces) that are capable of reflecting electromagnetic radiation. TheUVLED(s) and corresponding mirror(s) are positioned apart from oneanother so as to define a curing space. As noted, this curing spacepermits the passage of a coated glass fiber between the UVLED(s) and themirror(s). Moreover, the mirror(s) are typically positioned oppositecorresponding UVLED(s) to efficiently reflect the electromagneticradiation emitted from the UVLED(s) (and not already absorbed by theglass-fiber coating) into the curing space.

In another aspect, the present invention embraces a method for curing acoating on a glass fiber. UV radiation is emitted from one or moresources of electromagnetic radiation toward a curing space. A portion ofthe emitted UV radiation is transmitted entirely through the curingspace. At least some of the UV radiation transmitted entirely throughthe curing space is reflected toward the curing space (e.g., with amirror). A glass fiber having an incompletely cured coating is passedthrough the curing space to effect the absorption of both emitted andreflected UV radiation, thereby curing the coated glass fiber.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts a UVLED configuration for the curing of acoating upon a glass fiber.

FIG. 2 schematically depicts an alternative staggered UVLEDconfiguration for the curing of a coating upon a glass fiber.

FIG. 3 schematically depicts a staggered UVLED-mirror configuration forthe high-efficiency curing of a coating upon a glass fiber.

FIG. 4 schematically depicts an alternative staggered UVLED-mirrorconfiguration for the high-efficiency curing of a coating upon a glassfiber.

FIG. 5 schematically depicts a UVLED-mirror configuration having UVLEDsand mirrors positioned at an angle.

FIG. 6 schematically depicts a UVLED having an attached reflector forfocusing emitted UV radiation.

FIG. 7 depicts a cross-sectional view of an elliptic cylinder having areflective inner surface.

FIG. 8 schematically depicts an exemplary apparatus for curing a coatedglass fiber.

FIG. 9 schematically depicts a cross-sectional view of an exemplaryapparatus for curing a coated glass fiber.

DETAILED DESCRIPTION

In one aspect, the present invention embraces an apparatus for curingglass-fiber coatings.

The apparatus employs one or more UVLEDs that are configured to emitelectromagnetic radiation toward a drawn glass fiber to cure itscoating(s), typically polymeric coatings. In this regard, a plurality ofUV lamps may be positioned in various configurations, such as anapparatus 10 containing opposing UVLEDs 11 schematically depicted inFIG. 1 and an apparatus 20 containing staggered UVLEDs 11 depicted inFIG. 2. The UVLEDs 11 define a curing space 15 having a central axis 14along which an optical fiber (i.e., a glass fiber having one or morecoating layers) may pass during the curing process. A heat sink 12 maybe positioned adjacent to each UVLED 11 to dissipate generated heatenergy. A mounting plate 13 provides structural support for the UVLEDs11.

In one exemplary embodiment, the apparatus for curing glass-fibercoatings includes at least a UVLED-mirror pair, which includes (i) anultraviolet light emitting diode (UVLED) and (ii) a mirror (e.g., aconcave mirror) that is positioned to reflect and focus the UV-radiationemitted by the UVLED.

FIG. 3 schematically depicts an apparatus 30 containing a plurality ofUVLED-mirror pairs. As depicted in FIG. 3, the UVLEDs 11 andcorresponding mirrors 16 define a space through which the coated glassfiber can pass (i.e., a curing space 15). This curing space 15 furtherdefines a central axis 14, typically the axis along which a drawn glassfiber passes during the curing process (i.e., the glass fiber's curingaxis). Although the central axis 14 is typically vertical, non-vertical(e.g., horizontal) arrangements of the central axis 14 may also be used.Moreover, although the central axis may be centrally positioned in thecuring space, a central axis that is not centrally positioned within thecuring space is within the scope of the present invention.

Each UVLED 11 may be positioned such that it emits UV radiation towardthe central axis 14. In this regard, those of ordinary skill willappreciate that the power per unit area (i.e., the radiant flux) emittedby a UVLED decreases exponentially as the distance of the UVLED from theoptical fiber increases. Accordingly, each UVLED may be positioned at adistance of between about 1 millimeter and 100 millimeters (e.g.,typically between about 5 millimeters and 20 millimeters) from theoptical fiber to be cured (e.g., from the central axis).

Typically, a UVLED and its corresponding mirror are positioned so that asubstantial portion of the UV radiation incident to the optical fiber issubstantially perpendicular to the optical fiber (i.e., incident atabout a 90 degree angle).

Alternatively, the UVLED and/or its corresponding mirror may bepositioned at an angle so that most of the UV radiation incident to theoptical fiber is incident at an angle other than 90 degrees. FIG. 5schematically depicts an apparatus 50 containing UVLEDs 11 and mirrors16 positioned at an angle (i.e., an angle other than 90 degrees relativeto the optical fiber and the central axis 14).

It may be desirable for the power of the UV radiation incident to theoptical fiber to vary as the optical fiber progresses through theapparatus. Varying the power of the UV radiation may aid in the curingof the glass-fiber coating. Depending on the curing properties of aparticular coating, it may be desirable to initially expose the opticalfiber to high intensity UV radiation. Alternatively, it may be desirableto initially expose the optical fiber to lower intensity UV radiation(e.g., between about 10 percent and 50 percent of the maximum exposureintensity) before exposing the optical fiber to high intensity UVradiation (e.g., the maximum intensity to which the optical fiber isexposed). In this regard, initially exposing the optical fiber to lowerintensity UV radiation may be useful in controlling the generation offree radicals in an uncured coating. Those of ordinary skill in the artwill appreciate that if too many free radicals are present, many of thefree radicals may recombine rather than encourage the polymerization ofthe glass-fiber coating—an undesirable effect.

Varying the intensity of the UV radiation may, for example, be achievedby positioning the UVLED at an angle. As noted, the intensity of the UVradiation incident to a portion of the optical fiber may vary dependingupon the distance from that portion to the UVLED. Alternatively, in anapparatus containing a plurality of UVLEDs the intensity of the UVradiation output from the UVLEDs may vary.

As noted, each UVLED may be positioned such that it emits UV radiationtoward the central axis. That said, it will be appreciated by those ofordinary skill in the art that a UVLED does not emit UV radiation onlytoward a point or line, but rather emits UV radiation in manydirections. Thus, most of the UV radiation emitted by a UVLED will notstrike the glass-fiber coating to effect curing. However, in curing anoptical fiber coating, it is desirable that as much UV radiation aspossible strikes the optical fiber (i.e., a coated glass fiber). In thisregard, it will be further appreciated by those of ordinary skill in theart that curing occurs when UV radiation is absorbed by photoinitiatorsin the glass-fiber coating.

Thus, a UVLED may have one or more associated reflectors that focusemitted UV radiation toward the central axis. For example, FIG. 6depicts a cross-sectional view of a UVLED 11 having an attachedreflector 17. The reflector 17 may, for example and as depicted in FIG.6, have the shape of a rotated teardrop curve. By having a teardropshape, the reflector focuses UV radiation having various angles ofemittance toward the central axis. That said, the present inventionembraces UVLEDs with associated reflectors of various shapes (e.g., aspherical, elliptical, cylindrical or parabolic mirror).

A UVLED may have one or more lenses attached for focusing UV radiationemitted by the UVLED toward the central axis. Typically, a lens forfocusing electromagnetic radiation is convex (e.g., biconvex orplano-convex). In an alternative embodiment, a Fresnel lens may beemployed. Moreover, the lens may be selected such that the lens has afocal point at the glass fiber's curing axis (e.g., the central axis).

One or more mirrors may be positioned opposite a UVLED (i.e., on theopposite side of the central axis) so as to reflect the UV radiationemitted by the UVLED in the general direction of the central axis. Inother words, a UVLED emits UV radiation toward the curing space and thecentral axis, and its corresponding mirror(s) reflect emitted UVradiation not initially absorbed by optical fiber coatings back towardthe central axis (e.g., the glass fiber's curing axis). In this respect,FIG. 3 depicts UVLEDs 11 having a mirror 16 positioned opposite thecentral axis 14. Typically a mirror will be larger than itscorresponding UVLED. For example, a mirror may have a height of betweenabout one inch and 1.5 inches; however, other mirror sizes are withinthe scope of the present invention. The mirror may be formed from asuitable reflective material. For example, the mirror may be formed frompolished aluminum, polished stainless steel, or metalized glass (e.g.,silvered quartz).

The mirror may have a concave shape (i.e., the mirror is curved inwardstoward the curing space) so that the mirror focuses UV radiation emittedby the UVLED toward the central axis. By way of example, a concavemirror may have, inter alia, a cylindrical, elliptical, spherical, orparabolic shape (e.g., a paraboloid or a parabolic cylinder). A concavemirror can focus otherwise lost UV radiation (e.g., UV radiation notinitially incident to an optical fiber to be cured) onto an opticalfiber for curing, thus limiting the amount of wasted energy.

A UVLED-mirror pair as used herein is not limited to a single UVLEDpaired with a single mirror in a one-to-one relationship. A UVLED-mirrorpair may include a plurality of UVLEDs. Alternatively, a UVLED-mirrorpair may include a plurality of mirrors.

UVLEDs are capable of emitting wavelengths within a much smallerspectrum than conventional UV lamps. This promotes the use of more ofthe emitted electromagnetic radiation for curing.

In this regard, a UVLED for use in the present invention may be anysuitable LED that emits electromagnetic radiation having wavelengths ofbetween about 200 nanometers and 600 nanometers. By way of example, theUVLED may emit electromagnetic radiation having wavelengths of betweenabout 200 nanometers and 450 nanometers (e.g., between about 250nanometers and 400 nanometers). In a particular exemplary embodiment,the UVLED may emit electromagnetic radiation having wavelengths ofbetween about 300 nanometers and 400 nanometers. In another particularexemplary embodiment, the UVLED may emit electromagnetic radiationhaving wavelengths of between about 350 nanometers and 425 nanometers.

As noted, a UVLED typically emits a narrow band of electromagneticradiation. For example, the UVLED may substantially emit electromagneticradiation having wavelengths that vary by no more than about 30nanometers, typically no more than about 20 nanometers (e.g., a UVLEDemitting a narrow band of UV radiation mostly between about 375nanometers and 395 nanometers). It has been observed that a UVLEDemitting a narrow band of UV radiation mostly between about 395nanometers and 415 nanometers is more efficient than other narrow bandsof UV radiation. Moreover, it has been observed that UVLEDs emitting UVradiation slightly above the wavelength at which a glass-fiber coatinghas maximum absorption (e.g., about 360 nanometers) promote moreefficient polymerization than do UVLEDs emitting UV radiation at thewavelength at which the glass-fiber coating has maximum absorption.

In this regard, although an exemplary UVLED emits substantially all ofits electromagnetic radiation within a defined range (e.g., between 350nanometers and 450 nanometers, such as between 370 nanometers and 400nanometers), the UVLED may emit small amounts of electromagneticradiation outside the defined range. In this regard, 80 percent or more(e.g., at least about 90 percent) of the output (i.e., emittedelectromagnetic radiation) of an exemplary UVLED is typically within adefined range (e.g., between about 375 nanometers and 425 nanometers).

UVLEDs are typically much smaller than conventional UV lamps (e.g.,mercury bulbs). By way of example, the UVLED may be a 0.25-inch squareUVLED. The UVLED may be affixed to a platform (e.g., a 1-inch square orlarger mounting plate). Of course, other UVLED shapes and sizes arewithin the scope of the present invention. By way of example, a3-millimeter square UVLED may be employed.

Each UVLED may have a power output of as much as 32 watts (e.g., a UVLEDhaving a power input of about 160 watts and a power output of about 32watts). That said, UVLEDs having outputs greater than 32 watts (e.g., 64watts) may be employed as such technology becomes available. UsingUVLEDs with higher power output may be useful for increasing the rate atwhich optical fiber coatings cure, thus promoting increased productionline speeds.

Relative to other UV radiation sources, UVLED devices typically generatea smaller amount of heat energy. That said, to dissipate the heat energycreated by a UVLED, a heat sink may be located behind the UVLED (e.g.,opposite the portion of the UVLED that emits UV radiation). The heatsink may be one-inch square, although other heat sink shapes and sizesare within the scope of the present invention.

The heat sink may be formed of a material suitable for conducting heat(e.g., brass, aluminum, or copper). The heat sink may include a heatexchanger that employs a liquid coolant (e.g., chilled water), whichcirculates within the heat exchanger to draw heat from the UVLED.

Removing heat generated by the UVLED is important for several reasons.First, excess heat may slow the rate at which optical-fiber coatingscure. Furthermore, excess heat can cause the temperature of the UVLED torise, which can reduce UV-radiation output. Indeed, continuoushigh-temperature exposure can permanently reduce the UVLED's radiationoutput. With adequate heat removal, however, the UVLED may have a usefullife of 50,000 hours or more.

In another exemplary embodiment, the apparatus for curing glass-fibercoatings includes two or more UVLEDs.

For instance, the UVLEDs may be arranged in an array (e.g., a planar ornon-planar array, such as a three-dimensional array). With respect to athree-dimensional array, two or more UVLEDs may be configured in two ormore distinct planes that are substantially perpendicular to the centralaxis. As depicted in FIGS. 1 and 2, the UVLEDs 11, which emit UVradiation toward the curing space 15, are typically arrangedapproximately equidistant from the central axis 14.

The UVLEDs, for instance, may be arranged to define one or more helixes(i.e., a helical array of UVLEDs). In an array containing more than onehelix, the helixes may have the same chirality (i.e., asymmetrichandedness). Alternatively, at least one helix may have the oppositechirality (e.g., one helix may be right-handed and a second helix may beleft-handed).

The three-dimensional array of UVLEDs may define a curing space that issuitable for the passage of a coated glass fiber for curing. As before,the curing space defines a central axis (e.g., the axis along which adrawn glass fiber passes during the curing process).

The apparatus employing a three-dimensional array of UVLEDs for curingglass-fiber coatings may also include one or more mirrors for reflectingUV radiation into the curing space. For example, the apparatus mayinclude a plurality of the foregoing UVLED-mirror pairs. By way offurther example and as depicted in FIG. 4, a plurality of UVLEDs 11 maybe embedded in a mirror 46 (e.g., a mirror in the shape of a circular,elliptical, or parabolic cylinder), the interior of which defines thecuring space 15.

It will be appreciated by those of skill in the art that the position ofthe UVLEDs in a three-dimensional array may be defined by thecylindrical coordinate system (i.e., r, θ, z). Using the cylindricalcoordinate system and as described herein, the central axis of thecuring space defines a z-axis. Furthermore, as herein described and aswill be understood by those of ordinary skill in the art, the variable ris the perpendicular distance of a point to the z-axis (i.e., thecentral axis of the curing space). The variable θ describes the angle ina plane that is perpendicular to the z-axis. In other words and byreference to a Cartesian coordinate system (i.e., defining an x-axis, ay-axis, and a z-axis), the variable θ describes the angle between areference axis (e.g., the x-axis) and the orthogonal projection of apoint onto the x-y plane. Finally, the z variable describes the heightor position of a reference point along the z-axis.

Thus, a point is defined by its cylindrical coordinates (r, θ, z). ForUVLEDs employed in exemplary configurations, the variable r is usuallyconstant. Stated otherwise, the UVLEDs may be positioned approximatelyequidistant from the central axis (i.e., the z axis). Accordingly, tothe extent the variable r is largely fixed, the position of the UVLEDscan be described by the z and θ coordinates.

By way of example, a helical UVLED array may have a first UVLED at theposition (1, 0, 0), where r is fixed at a constant distance (i.e.,represented here as a unitless 1). Additional UVLEDs may be positioned,for example, every 90° (i.e., π/2) with a Δz of 1 (i.e., a positionalstep change represented here as a unitless 1). Thus, a second UVLEDwould have the coordinates (1, π/2, 1), a third UVLED would have thecoordinates (1, π, 2), and a fourth UVLED would have the coordinates (1,3π/2, 3), thereby defining a helical configuration.

Those having ordinary skill in the art will appreciate that, as used inthe foregoing example, the respective distances r and z need not beequivalent. Moreover, those having ordinary skill in the art willfurther appreciate that several UVLEDs in an array as herein disclosedneed not be offset by 90° (e.g., π/2, π, 3π/2, etc.). For example, theUVLEDs may be offset by 60° (e.g., π/3, 2π/3, π, etc.) or by 120° (e.g.,2π/3, 4π/3, 2π, etc.). Indeed, the UVLEDs in an array as discussedherein need not follow a regularized helical rotation.

It will be further appreciated by those of ordinary skill in the artthat UVLEDs may absorb incident electromagnetic radiation, which mightdiminish the quantity of reflected UV radiation available for absorptionby the glass-fiber coating. See FIG. 1. Therefore, in an apparatus forcuring glass-fiber coatings having a plurality of UVLEDs, it may bedesirable to position the UVLEDs in a way that reduces UV radiationincident to the UVLEDs. See FIGS. 2, 3, and 4.

In an exemplary embodiment described using the cylindrical coordinatesystem, UVLEDs with a Δθ0 of π (i.e., UVLEDs positioned on oppositesides of a UVLED array) may be positioned so that they have a Δz that isat least the height of the UVLED. Thus, if each UVLED has a height of0.5 inch, a

UVLED with a Δθ of π should have a Δz of at least 0.5 inch. It isthought that this would reduce the absorption by one UVLED of UVradiation emitted by another UVLED, thereby increasing the availabilityof UV radiation for reflection by one or more mirrors and absorption bythe glass-fiber coating.

Alternatively (or in accordance with the foregoing discussion), theUVLEDs may employ a reflective surface (e.g., a surface coating) thatpromotes reflection of incident electromagnetic radiation yet permitsthe transmission of emitted electromagnetic radiation.

In view of the foregoing, yet another exemplary embodiment employs aplurality of UVLED-mirror pairs that are arranged in a three dimensionalconfiguration. In particular, the plurality of UVLED-mirror pairs sharea common curing space defining a common central axis. In an exemplaryconfiguration, the UVLED-mirror pairs may be helically arranged (e.g.,configured in a 60°, 90°, or 120° helical array).

In yet another exemplary embodiment, the apparatus for curingglass-fiber coatings includes one or more UVLEDs positioned within acylindrical cavity (or a substantially cylindrical cavity) having areflective inner surface (e.g., made from stainless steel or silveredquartz, or otherwise including a reflective inner surface).

The interior of the cylindrical cavity defines the curing space. Asbefore, the curing space defines a curing axis (e.g., a central axis)along which a drawn glass fiber passes during the curing process.Moreover, one or more UVLEDs may be positioned within the cylindricalcavity such that they emit UV radiation in the direction of the curingaxis.

In a typical embodiment, the cylindrical cavity has a non-circularelliptical cross-section. In other words, the cylindrical cavitytypically has the shape of an elliptic cylinder. For an ellipticcylinder the curing axis may correspond with one of the two line focidefined by the elliptic cylinder. In addition, each UVLED may bepositioned along the other line focus such that they emit UV radiationin the general direction of the curing axis. This arrangement is usefulfor improving curing efficiency, because any electromagnetic radiationthat is emitted from one line focus (regardless of direction) will bedirected toward the other line focus after being reflected at the innersurface of the cylinder. This principle is illustrated in FIG. 7, whichdepicts a cross-section of a reflective elliptic cylinder 55 having afirst line focus 51 and a second line focus 52. As depicted in FIG. 7,each UV ray 53 emitted from the first line focus 51 will intersect thesecond line focus 52.

That said, the UV radiation emitted from a UVLED is not emitted from asingle point. Therefore and because of the small size of a coated glassfiber, it is desirable to use small UVLEDs (e.g., a 3-millimeter squareUVLED or a 1-millimeter square UVLED), because a greater percentage ofemitted and reflected light from a small UVLED will be incident to thecoated glass fiber.

In accordance with the foregoing, FIGS. 8-9 depict an exemplaryapparatus 60 for curing a coated glass fiber 66. The apparatus 60includes a substantially cylindrical cavity 65 having an ellipticalshape and having a reflective inner surface. The cavity 65 defines afirst line focus 61 and a second line focus 62. A plurality of UVLEDs 64are positioned along the first line focus 61. The second line focus 62further defines a curing axis along which a coated glass fiber 66 passesso it can be cured. As depicted in FIG. 9, UV rays 63 emitted from theUVLEDs 64 may reflect off the inner surface of the cavity 65 such thatthe reflected UV rays 63 are incident to the coated glass fiber 66. Tofacilitate uniform curing of the coated glass fiber 66, some of theUVLEDs 64 may be differently oriented. For example, a second apparatus70 for curing a glass fiber could have a different orientation than theapparatus 60 (e.g., the second apparatus 70 may have UVLEDs positionedalong a line focus 71 that differs from the first line focus 61).

In an alternative exemplary embodiment, rather than placing the UVLEDsalong one of the line foci, each UVLED may include a lens for focusingemitted UV radiation. In particular, each lens may have a focus at oneof the two line foci (e.g., the line focus not defining a curing axis).By including a lens with each UVLED, the efficiency of the apparatus canbe further improved.

An apparatus as described herein may include a dark space between one ormore UVLEDs. In other words, the apparatus may include a space in whichsubstantially no UV radiation is incident to the optical fiber beingcured. A pause in the curing process provided by a dark space can helpto ensure even and efficient curing of the optical fiber coatings. Inparticular, a dark space may be useful in preventing too many freeradicals from being present in a glass-fiber coating before it is cured(i.e., dark space helps to control free-radical generation).

For example, it may be desirable to initially expose an optical fiber tolow power UV radiation and then pass the optical fiber through a darkspace. After the optical fiber passes through a dark space, it isexposed to higher power UV radiation to complete the curing process. Acuring apparatus employing dark space is disclosed in commonly assignedU.S. Pat. No. 7,322,122 for a Method and Apparatus for Curing a FiberHaving at Least Two Fiber Coating Curing Stages, which is herebyincorporated by reference in its entirety.

An apparatus for curing glass-fiber coatings may include a controlcircuit for controlling the UV radiation output from the UVLED. Thecontrol circuit may be used to vary the intensity of the UV radiation asan optical fiber progresses through the apparatus.

For example, to ensure that the optical fiber receives a consistent doseof ultraviolet radiation, the UV radiation output of the UVLEDs may varywith the speed at which the optical fiber passes through the apparatus.That is to say, at higher speeds (i.e., the speed the optical fiberpasses through the apparatus) the output intensity of the UVLEDs may begreater than the output intensity at lower speeds. The output intensityof the UVLEDs may be controlled by reducing (or increasing) the currentflowing to the UVLEDs.

In another aspect, the present invention embraces a method of employingthe foregoing apparatus to cure a coating on a glass fiber (i.e., insitu curing).

In an exemplary method, a glass fiber is drawn from an optical preformand coated with a UV curable material. UV radiation is emitted from oneor more sources of electromagnetic radiation (e.g., one or more UVLEDs)toward a curing space (e.g., in the general direction of the coatedglass fiber). A portion, if not most, of the emitted UV radiation istransmitted entirely through the curing space. Typically, at least some,if not most, of the UV radiation transmitted entirely through the curingspace (i.e., at least some UV radiation that has not been absorbed) isreflected (e.g., with a mirror) toward the curing space. A glass fiberhaving an incompletely cured coating is continuously passed through thecuring space to effect the absorption of emitted and reflected UVradiation. The absorption of the UV radiation cures the glass-fibercoating. Moreover, and in accordance with the foregoing, to improve thecuring rate, at least a portion of the reflected UV radiation may befocused on the glass fiber (e.g., by using a concave mirror to reflectUV radiation toward the curing space's curing axis).

In accordance with the foregoing, the resulting optical fiber includesone or more coating layers (e.g., a primary coating and a secondarycoating). At least one of the coating layers—typically the secondarycoating—may be colored and/or possess other markings to help identifyindividual fibers. Alternatively, a tertiary ink layer may surround theprimary and secondary coatings.

For example, the resulting optical fiber may have one or more coatings(e.g., the primary coating) that comprise a UV-curable, urethaneacrylate composition. In this regard, the primary coating may includebetween about 40 and 80 weight percent of polyether-urethane acrylateoligomer as well as photoinitiator, such as LUCERIN TPO, which iscommercially available from BASF. In addition, the primary coatingtypically includes one or more oligomers and one or more monomerdiluents (e.g., isobornyl acrylate), which may be included, forinstance, to reduce viscosity and thereby promote processing. Exemplarycompositions for the primary coating include UV-curable urethaneacrylate products provided by DSM Desotech (Elgin, Ill.) under varioustrade names, such as DeSolite® DP 1011, DeSolite® DP 1014, DeSolite® DP1014XS, and DeSolite® DP 1016.

Those having ordinary skill in the art will recognize that an opticalfiber with a primary coating (and an optional secondary coating and/orink layer) typically has an outer diameter of between about 235 micronsand about 265 microns (μm). The component glass fiber itself (i.e., theglass core and surrounding cladding layers) typically has a diameter ofabout 125 microns, such that the total coating thickness is typicallybetween about 55 microns and 70 microns.

With respect to an exemplary optical fiber achieved according to thepresent curing method, the component glass fiber may have an outerdiameter of about 125 microns. With respect to the optical fiber'ssurrounding coating layers, the primary coating may have an outerdiameter of between about 175 microns and about 195 microns (i.e., aprimary coating thickness of between about 25 microns and 35 microns)and the secondary coating may have an outer diameter of between about235 microns and about 265 microns (i.e., a secondary coating thicknessof between about 20 microns and 45 microns). Optionally, the opticalfiber may include an outermost ink layer, which is typically between twoand ten microns thick.

In an alternative embodiment, the resulting optical fiber may possess areduced diameter (e.g., an outermost diameter between about 150 micronsand 230 microns). In this alternative optical fiber configuration, thethickness of the primary coating and/or secondary coating is reduced,while the diameter of the component glass fiber is maintained at about125 microns. By way of example, in such embodiments the primary coatinglayer may have an outer diameter of between about 135 microns and about175 microns (e.g., about 160 microns), and the secondary coating layermay have an outer diameter of between about 150 microns and about 230microns (e.g., more than about 165 microns, such as 190-210 microns orso). In other words, the total diameter of the optical fiber is reducedto less than about 230 microns (e.g., about 200 microns).

Exemplary coating formulations for use with the apparatus and methoddescribed herein are disclosed in the following commonly assignedapplications, each of which is incorporated by reference in itsentirety: U.S. Patent Application No. 61/112,595 for aMicrobend-Resistant Optical Fiber, filed Nov. 7, 2008, (Overton);International Patent Application Publication No. WO 2009/062131 A1 for aMicrobend-Resistant Optical Fiber, (Overton); U.S. Patent ApplicationPublication No. US2009/0175583 A1 for a Microbend-Resistant OpticalFiber, (Overton); and U.S. patent application Ser. No. 12/614,011 for aReduced-Diameter Optical Fiber, filed Nov. 6, 2009, (Overton).

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications: U.S. Pat. No.4,838,643 for a Single Mode Bend Insensitive Fiber for Use in FiberOptic Guidance Applications (Hodges et al.); U.S. Pat. No. 7,623,747 fora Single Mode Optical Fiber (de Montmorillon et al.); U.S. Pat. No.7,587,111 for a Single-Mode Optical Fiber (de Montmorillon et al.); U.S.Pat. No. 7,356,234 for a Chromatic Dispersion Compensating Fiber (deMontmorillon et al.); U.S. Pat. No. 7,483,613 for a Chromatic DispersionCompensating Fiber (de Montmorillon et al.); U.S. Pat. No. 7,555,186 foran Optical Fiber (Flammer et al.); U.S. Patent Application PublicationNo. US2009/0252469 A1 for a Dispersion-Shifted Optical Fiber (Sillard etal.); U.S. patent application Ser. No. 12/098,804 for a TransmissionOptical Fiber Having Large Effective Area (Sillard et al.), filed Apr.7, 2008; U.S. Patent Application Publication No. US2009/0279835 A1 for aSingle-Mode Optical Fiber Having Reduced Bending Losses, filed May 6,2009, (de Montmorillon et al.); U.S. Patent Application Publication No.US2009/0279836 A1 for a Bend-Insensitive Single-Mode Optical Fiber,filed May 6, 2009, (de Montmorillon et al.); U.S. patent applicationSer. No. 12/489,995 for a Wavelength Multiplexed Optical System withMultimode Optical Fibers, filed Jun. 23, 2009, (Lumineau et al.); U.S.patent application Ser. No. 12/498,439 for a Multimode Optical Fibers,filed Jul. 7, 2009, (Gholami et al.); U.S. patent application Ser. No.12/614,172 for a Multimode Optical System, filed Nov. 6, 2009, (Gholamiet al.); U.S. patent application Ser. No. 12/617,316 for an AmplifyingOptical Fiber and Method of Manufacturing, filed Nov. 12, 2009,(Pastouret et al.) U.S. patent application Ser. No. 12/629,495 for anAmplifying Optical Fiber and Production Method, filed Dec. 2, 2009,(Pastouret et al.); U.S. patent application Ser. No. 12/633,229 for anIonizing Radiation-Resistant Optical Fiber Amplifier, filed Dec. 8,2009, (Regnier et al.); and U.S. patent application Ser. No. 12/636,277for a Buffered Optical Fiber, filed Dec. 11, 2009, (Testu et al.).

To supplement the present disclosure, this application furtherincorporates entirely by reference the following commonly assignedpatents, patent application publications, and patent applications: U.S.Pat. No. 5,574,816 for Polypropylene-Polyethylene Copolymer Buffer Tubesfor Optical Fiber Cables and Method for Making the Same; U.S. Pat. No.5,717,805 for Stress Concentrations in an Optical Fiber Ribbon toFacilitate Separation of Ribbon Matrix Material; U.S. Pat. No. 5,761,362for Polypropylene-Polyethylene Copolymer Buffer Tubes for Optical FiberCables and Method for Making the Same; U.S. Pat. No. 5,911,023 forPolyolefin Materials Suitable for Optical Fiber Cable Components; U.S.Pat. No. 5,982,968 for Stress Concentrations in an Optical Fiber Ribbonto Facilitate Separation of Ribbon Matrix Material; U.S. Pat. No.6,035,087 for an Optical Unit for Fiber Optic Cables; U.S. Pat. No.6,066,397 for Polypropylene Filler Rods for Optical Fiber CommunicationsCables; U.S. Pat. No. 6,175,677 for an Optical Fiber Multi-Ribbon andMethod for Making the Same; U.S. Pat. No. 6,085,009 for Water BlockingGels Compatible with Polyolefin Optical Fiber Cable Buffer Tubes andCables Made Therewith; U.S. Pat. No. 6,215,931 for FlexibleThermoplastic Polyolefin Elastomers for Buffering Transmission Elementsin a Telecommunications Cable; U.S. Pat. No. 6,134,363 for a Method forAccessing Optical Fibers in the Midspan Region of an Optical FiberCable; U.S. Pat. No. 6,381,390 for a Color-Coded Optical Fiber Ribbonand Die for Making the Same; U.S. Pat. No. 6,181,857 for a Method forAccessing Optical Fibers Contained in a Sheath; U.S. Pat. No. 6,314,224for a Thick-Walled Cable Jacket with Non-Circular Cavity Cross Section;U.S. Pat. No. 6,334,016 for an Optical Fiber Ribbon Matrix MaterialHaving Optimal Handling Characteristics; U.S. Pat. No. 6,321,012 for anOptical Fiber Having Water Swellable Material for Identifying Groupingof Fiber Groups; U.S. Pat. No. 6,321,014 for a Method for ManufacturingOptical Fiber Ribbon; U.S. Pat. No. 6,210,802 for Polypropylene FillerRods for Optical Fiber Communications Cables; U.S. Pat. No. 6,493,491for an Optical Drop Cable for Aerial Installation; U.S. Pat. No.7,346,244 for a Coated Central Strength Member for Fiber Optic Cableswith Reduced Shrinkage; U.S. Pat. No. 6,658,184 for a Protective Skinfor Optical Fibers; U.S. Pat. No. 6,603,908 for a Buffer Tube thatResults in Easy Access to and Low Attenuation of Fibers Disposed WithinBuffer Tube; U.S. Pat. No. 7,045,010 for an Applicator for High-SpeedGel Buffering of Flextube Optical Fiber Bundles; U.S. Pat. No. 6,749,446for an Optical Fiber Cable with Cushion Members Protecting Optical FiberRibbon Stack; U.S. Pat. No. 6,922,515 for a Method and Apparatus toReduce Variation of Excess Fiber Length in Buffer Tubes of Fiber OpticCables; U.S. Pat. No. 6,618,538 for a Method and Apparatus to ReduceVariation of Excess Fiber Length in Buffer Tubes of Fiber Optic Cables;U.S. Pat. No. 7,322,122 for a Method and Apparatus for Curing a FiberHaving at Least Two Fiber Coating Curing Stages; U.S. Pat. No. 6,912,347for an Optimized Fiber Optic Cable Suitable for Microduct BlownInstallation; U.S. Pat. No. 6,941,049 for a Fiber Optic Cable Having NoRigid Strength Members and a Reduced Coefficient of Thermal Expansion;U.S. Pat. No. 7,162,128 for Use of Buffer Tube Coupling Coil to PreventFiber Retraction; U.S. Pat. No. 7,515,795 for a Water-Swellable Tape,Adhesive-Backed for Coupling When Used Inside a Buffer Tube (Overton etal.); U.S. Patent Application Publication No. 2008/0292262 for aGrease-Free Buffer Optical Fiber Buffer Tube Construction Utilizing aWater-Swellable, Texturized Yarn (Overton et al.); European PatentApplication Publication No. 1,921,478 A1, for a TelecommunicationOptical Fiber Cable (Tatat et al.); U.S. Pat. No. 7,570,852 for anOptical Fiber Cable Suited for Blown Installation or PushingInstallation in Microducts of Small Diameter (Nothofer et al.); U.S.Patent Application Publication No. US 2008/0037942 A1 for an OpticalFiber Telecommunications Cable (Tatat); U.S. Pat. No. 7,599,589 for aGel-Free Buffer Tube with Adhesively Coupled Optical Element (Overton etal.); U.S. Pat. No. 7,567,739 for a Fiber Optic Cable Having aWater-Swellable Element (Overton); U.S. Patent Application PublicationNo. US2009/0041414 A1 for a Method for Accessing Optical Fibers within aTelecommunication Cable (Lavenne et al.); U.S. Patent ApplicationPublication No. US2009/0003781 A1 for an Optical Fiber Cable Having aDeformable Coupling Element (Parris et al.); U.S. Patent ApplicationPublication No. US2009/0003779 A1 for an Optical Fiber Cable HavingRaised Coupling Supports (Parris); U.S. Patent Application PublicationNo. US2009/0003785 A1 for a Coupling Composition for Optical FiberCables (Parris et al.); U.S. Patent Application Publication No.US2009/0214167 A1 for a Buffer Tube with Hollow Channels, (Lookadoo etal.); U.S. patent application Ser. No. 12/466,965 for an Optical FiberTelecommunication Cable, filed May 15, 2009, (Tatat); U.S. patentapplication Ser. No. 12/506,533 for a Buffer Tube with AdhesivelyCoupled Optical Fibers and/or Water-Swellable Element, filed Jul. 21,2009, (Overton et al.); U.S. patent application Ser. No. 12/557,055 foran Optical Fiber Cable Assembly, filed Sep. 10, 2009, (Barker et al.);U.S. patent application Ser. No. 12/557,086 for a High-Fiber-DensityOptical Fiber Cable, filed Sep. 10, 2009, (Louie et al.); U.S. patentapplication Ser. No. 12/558,390 for a Buffer Tubes for Mid-Span Storage,filed Sep. 11, 2009, (Barker); U.S. patent application Ser. No.12/614,692 for Single-Fiber Drop Cables for MDU Deployments, filed Nov.9, 2009, (Overton); U.S. patent application Ser. No. 12/614,754 forOptical-Fiber Loose Tube Cables, filed Nov. 9, 2009, (Overton); U.S.patent application Ser. No. 12/615,003 for a Reduced-Size Flat DropCable, filed Nov. 9, 2009, (Overton et al.); U.S. patent applicationSer. No. 12/615,106 for ADSS Cables with High-Performance Optical Fiber,filed Nov. 9, 2009, (Overton); U.S. patent application Ser. No.12/615,698 for Reduced-Diameter Ribbon Cables with High-PerformanceOptical Fiber, filed Nov. 10, 2009, (Overton); U.S. patent applicationSer. No. 12/615,737 for a Reduced-Diameter, Easy-Access Loose TubeCable, filed Nov. 10, 2009, (Overton); U.S. patent application Ser. No.12/642,784 for a Method and Device for Manufacturing an Optical Preform,filed Dec. 19, 2009, (Milicevic et al.); and U.S. patent applicationSer. No. 12/648,794 for a Perforated Water-Blocking Element, filed Dec.29, 2009, (Parris).

In the specification and/or figures, typical embodiments of theinvention have been disclosed. The present invention is not limited tosuch exemplary embodiments. The figures are schematic representationsand so are not necessarily drawn to scale. Unless otherwise noted,specific terms have been used in a generic and descriptive sense and notfor purposes of limitation.

1. An apparatus for curing a coating upon a glass fiber, the apparatuscomprising: a UVLED-mirror pair, said UVLED-mirror pair comprising (i) aUVLED for emitting electromagnetic radiation and (ii) a correspondingmirror for reflecting electromagnetic radiation; wherein said UVLED andsaid mirror define therebetween a curing space for the passage of acoated glass fiber between said UVLED and said mirror; and wherein saidmirror is positioned opposite said UVLED to reflect the electromagneticradiation emitted from said UVLED into the curing space.
 2. An apparatusaccording to claim 1, comprising a plurality of UVLED-mirror pairs, eachsaid UVLED-mirror pair comprising (i) at least one UVLED for emittingelectromagnetic radiation and (ii) at least one mirror for reflectingelectromagnetic radiation, wherein said UVLED-mirror pairs furtherdefine the curing space.
 3. An apparatus according to claim 2, wherein:the curing space defines a central axis; and said UVLED-mirror pairs areconfigured in two or more distinct planes that are substantiallyperpendicular to the central axis.
 4. An apparatus according to claim 3,wherein said UVLED-mirror pairs are helically configured.
 5. Anapparatus according to claim 2, wherein at least two of said UVLEDs emitelectromagnetic radiation at different output intensities.
 6. Anapparatus according to claim 2, wherein each said UVLED has a poweroutput of at least about 30 watts.
 7. An apparatus according to claim 2,comprising a dark space between at least two of said UVLEDs.
 8. Anapparatus according to claim 2, comprising a heat sink for dissipatingheat from each said UVLED.
 9. An apparatus according to claim 1, whereinsubstantially all of the electromagnetic radiation emitted by said UVLEDhas wavelengths of between about 200 nanometers and 600 nanometers. 10.An apparatus according to claim 1, wherein at least 90 percent of theelectromagnetic radiation emitted by said UVLED has wavelengths ofbetween about 250 nanometers and 400 nanometers.
 11. An apparatusaccording to claim 1, wherein at least 80 percent of the electromagneticradiation emitted by said UVLED has wavelengths of between about 300nanometers and 450 nanometers.
 12. An apparatus according to claim 1,wherein at least 80 percent of the electromagnetic radiation emitted bysaid UVLED has wavelengths of between about 375 nanometers and 425nanometers.
 13. An apparatus according to claim 1, wherein said UVLEDemits electromagnetic radiation of wavelengths mostly between about 395nanometers and 415 nanometers.
 14. An apparatus according to claim 1,wherein at least 80 percent of the electromagnetic radiation emitted bysaid UVLED has wavelengths within a 30-nanometer range.
 15. An apparatusaccording to claim 1, wherein said UVLED has a power output of at leastabout 30 watts.
 16. An apparatus according to claim 1, wherein saidUVLED-mirror pair comprises a plurality of UVLEDs.
 17. An apparatusaccording to claim 1, wherein said UVLED-mirror pair comprises a concavemirror.
 18. An apparatus according to claim 1, wherein said UVLED-mirrorpair comprises a parabolic mirror, a spherical mirror, and/or acylindrical mirror.
 19. An apparatus according to claim 1, wherein saidUVLED-mirror pair comprises a plurality of mirrors positioned oppositesaid UVLED to reflect the electromagnetic radiation emitted from saidUVLED into the curing space.
 20. An apparatus according to claim 1,comprising a heat sink for dissipating heat from said UVLED.
 21. Anapparatus according to claim 20, wherein said heat sink comprises a heatexchanger that employs a liquid coolant.
 22. An apparatus according toclaim 1, comprising a reflector for focusing UV radiation toward thecoated glass fiber, wherein said reflector is attached to said UVLED.23. An apparatus according to claim 22, wherein said reflector has theshape of a rotated teardrop curve.
 24. An apparatus according to claim1, comprising a lens for focusing UV radiation toward the coated glassfiber, said lens attached to said UVLED.
 25. An apparatus according toclaim 1, comprising a control circuit for controlling the UV radiationoutput from said UVLED.
 26. An apparatus according to claim 25, whereinsaid control circuit adjusts the intensity of electromagnetic radiationoutput from said UVLED in response to a change in the speed at which thecoated glass fiber passes through the apparatus.
 27. An apparatus forcuring a coated glass fiber, comprising: a substantially cylindricalcavity having an elliptical cross-section, said cavity having areflective inner surface; and one or more UVLEDs positioned within saidcavity; wherein said cavity defines a first line focus and a second linefocus, said second line focus defining a curing axis.
 28. An apparatusaccording to claim 27, wherein said UVLEDs are positioned along saidfirst line focus to emit UV radiation in the direction of said curingaxis.
 29. An apparatus according to claim 27, wherein at least one ofsaid UVLEDs includes a lens for focusing UV radiation, said lens havinga focus along said first line focus.
 30. An apparatus for curing acoating upon a glass fiber, the apparatus comprising a three-dimensionalhelical array of UVLEDs, said three-dimensional helical array of UVLEDsdefining a glass-fiber curing space having a central axis, wherein eachof said UVLEDs emits electromagnetic radiation toward the glass-fibercuring space.
 31. An apparatus according to claim 30, comprising aplurality of three-dimensional helical arrays of UVLEDs, wherein each ofsaid UVLEDs emits electromagnetic radiation toward the glass-fibercuring space.
 32. An apparatus according to claim 31, wherein each ofsaid three-dimensional helical arrays of UVLEDs has the same chirality.33. An apparatus according to claim 31, wherein at least two of saidthree-dimensional helical arrays of UVLEDs have opposite chirality. 34.An apparatus according to claim 30, comprising one or more mirrors forreflecting electromagnetic radiation toward the glass-fiber curingspace.
 35. A method for curing a coating on a glass fiber, comprising:emitting UV radiation from one or more sources of electromagneticradiation toward a curing space; transmitting a portion of the emittedUV radiation entirely through the curing space; reflecting toward thecuring space at least some of the UV radiation transmitted entirelythrough the curing space; and passing through the curing space a glassfiber having an incompletely cured coating to effect the absorption ofboth emitted and reflected UV radiation.
 36. The method according toclaim 35, wherein the step of emitting UV radiation comprises emittingUV radiation from one or more UVLEDs.
 37. The method according to claim35, wherein the step of passing the glass fiber through the curing spacesubstantially cures the coating on the glass fiber.
 38. The methodaccording to claim 35, wherein the step of reflecting at least some ofthe UV radiation comprises reflecting with a mirror at least some of theUV radiation toward the curing space.
 39. The method according to claim35, wherein the step of reflecting at least some of the UV radiationcomprises focusing with a concave mirror at least some of the UVradiation toward the glass fiber having an incompletely cured coating.40. The method according to claim 39, wherein focusing at least some ofthe UV radiation toward the glass fiber is achieved with a parabolicmirror, a spherical mirror, and/or a cylindrical mirror.
 41. The methodaccording to claim 35, wherein the step of emitting UV radiationcomprises focusing with a lens at least some of the emitted UVradiation.
 42. The method according to claim 41, wherein the step ofpassing a glass fiber through the curing space comprises passing theglass fiber through the focus of the lens.